Throttle Winch Control

I all the time sit up for Saturdays (as a result of it’s the begin of my regular three day weekend).  I work a 4 10 hour days shift, normally Tuesday – Friday so when quitting time rolls round on Friday, I sit up for not being again within the workplace till Tuesday morning.  This specific Saturday was going to be a extra enjoyable than most as a result of an excellent pal of mine, MikeW, that I by no means get to spend sufficient time with was coming over at 9:00 AM.  We had talked earlier within the week about performing some Jeep wrenching and a few laptop stuff.  When I instructed him I had gotten my new Throttle Winch Control from Kwan Motorsystems in San Jose, CA., Mike was greater than able to help.  So, I acquired up early on Saturday, tossed the canine at the back of the TJ, and headed out to the desert to allow them to blow off some steam.  We acquired again at about 8:30 AM which gave me sufficient time to get issues arrange for Mike’s arrival.  At 9:00, Mike pulled up in his TJ and we acquired began on the day’s agenda.

You is perhaps questioning simply what the heck a Throttle Winch Control (TWC) is suppose to do.  It is a twin function “black field” controller that capabilities as a throttle management and likewise as a winch controller.  More accurately stated, it’s a totally digital MOSFET controller that interfaces together with your manufacturing facility TJ cruise management switches to do all its cool stuff.  The cruise management switches on the left facet of the steering wheel, ON/OFF and SET, are used for the winch.  ON/OFF turns into Winch Out (simple to recollect….Out is an “O” phrase and goes with On/Off).  The SET swap powers the winch in.  On the correct facet of the steering wheel, RESUME/ACCEL will increase engine RPM, COAST decreases it, and CANCEL clears any RPM setting and restores the engine to a standard idle.  When the TWC is turned on with its energy swap, the throttle management mode is offered and the winch capabilities are disabled.  To additionally allow the winch controls, maintain the SET button (left hand facet of the steering wheel) down whereas turning on the TWC energy swap.  The TWC disables the manufacturing facility cruise management throughout operation.  To allow regular cruise management performance, flip off the TWC and ignition key.  When you begin the engine once more (with the TWC off), the manufacturing facility cruise can be totally practical.

With that out of the best way, lets get to the set up.  Besides, Mike has been ready now for about quarter-hour for me to get this present on the highway! 

There is one different factor I ought to point out.  For some motive, Jeep determined to vary among the wiring harness within the ’03 mannequin.  The TWC set up instructions clearly name out the manufacturing facility connector numbers and wire colours for each manufacturing facility harness setups .  What you will notice from right here on, within the pics and in my feedback, are relevant to my ’98 TJ.  If somebody desires feedback and pics for an ’03 TJ, please be at liberty to contact me and organize for supply of an ’03 Jeep.  (you received’t get it again both)  If you will have one thing newer than an ’03, you have to to contact Kwan Motorsystems for particulars.
 

The TWC is just about a plug and play controller.  It comes with the a beneficiant quantity of wire and cable hooked up to the management field.  A plastic bag containing crimp on connectors, fuse, wire, screws, and a swap.  The 5 web page proprietor’s handbook covers set up and operation of the TWC.  The set up instructions are detailed and embrace diagrams to assist find the wire connection factors in your TJ and likewise present the pin diagrams for the manufacturing facility connectors.  I particularly appreciated the nicely drawn block diagram that exhibits the entire TWC wire colours and their corresponding connection factors within the TJ (with manufacturing facility wire colours).  This sort of “every little thing at a look” gave me a fast overview of what wanted to be executed with out sifting via the written particulars.  Those with {an electrical} background ought to know what I imply.  That being stated, I adopted the entire written directions for wiring up every group of wires to make sure I didn’t miss something (and it serves as a great way to 2nd examine your self when hooking up the wires).  I believe it’s protected to say that nobody needs to mess up a wiring challenge.

SAFETY FIRST!  The set up instructions say to disconnect the battery earlier than beginning on this challenge.  You can be attaching wires to your winch management solenoids and in case your winch is like mine, it’s wired straight to the battery.  I personally don’t need to do any 12 volt welding whereas I attempt to connect wires to the winch.

I mounted the TWC field within the automobile on the motive force’s facet kick panel.  The management field is just not waterproof.  If you suppose you is perhaps taking yours for a swim (I’ve seen a few of these “caught” photos that get posted within the on-line boards), I’d counsel contacting Kwan Motorsystems for extra info.  It would seem that it might be pretty easy to waterproof the management field, however don’t take my phrase on this.  Talk with the parents at Kwan and comply with their strategies.

With the management field mounted, I made a decision to discover a appropriate location for the ability swap.  With the assistance of a rotary cutter (aka., Dremel software), I lower the requisite rectangular formed gap for the double pole single throw (DPST) swap.  In case you had been questioning, the opposite swap controls the relay for my rock lights. 

After the mounting gap for the swap was full, it was time to start out hooking up wires to their numerous places.  A variety of wires are hooked up within the close to neighborhood of the place I mounted the management field.  There is a big group of manufacturing facility wiring harness connectors up beneath the motive force’s facet sprint space.  So that I may see these somewhat higher, I opted to eliminated the speaker on the motive force’s facet of the sprint.  While I made no connections by way of this sprint opening, it allowed me to extra simply establish the varied connectors I’d be working with and it permits somewhat extra mild to get into that darkish space (in fact, a bother mild will do this too).  The TWC set up instructions don’t counsel you take away the speaker, simply in case you had been questioning. 

Throttle Winch Control

First on the record of wires to route and fasten had been the 12V energy and floor leads.  The +12V fused lead is hooked up to the pink wire on C204, pin 10.  Its the one pink wire on this pink connector so it’s fairly simple to identify. 

Using a crimp on splice connector, join this pink wire utilizing the provided pink wire and fuse holder to the ability swap.  The different contact on the swap is related to the pink wire coming from the TWC field. 

I used a manufacturing facility grounding level for the bottom wire coming from the ability swap.  It is positioned on the kick panel proper subsequent to the place I mounted the TWC field.  The black wire from the TWC field is routed to the swap after which a floor wire from the swap is related to the above chassis floor screw.

I’ve hooked up the crimp on spade lugs to the entire swap leads.  I choose to go away an extended pig tail, maybe longer than some people do.  In this case, it is going to tuck again properly beneath the middle console and nobody will see the additional wire.  I maintain a provide of zip ties and used some small ones to bundle these energy wires collectively.

Here is a close-up of the ability swap.  It exhibits the right connections factors for the constructive (pink) wires.  Obviously, the 2 unfavourable (black) wires are related to the opposite two swap terminals. 

Throttle Winch Control

With the ability leads out of the best way, Mike and I turned our consideration to getting the lead from the cruise management switches interfaced to the TWC field.  The blue connector, C108, has a pink wire with a light-weight inexperienced tracer related to pin 10.  I’m pointing to pin 10 with the needle noise pliers within the above pic. 

With a small sharp knife, I eliminated among the black harness wrap from the wire bundle so I may get a little bit of slack for this wire.  With the wire lower a few inches from the connector, the TWC inexperienced wire is related to the brief wire nonetheless hooked up to pin 10 of the connector.  The TWC white wire is related to the opposite finish of the lower wire.  Crimp on butt splices the place used for each connections.  I fastidiously re-wrapped the wire bundle with electrical tape.  The butt splices trigger a little bit of a bulge beneath the tape however that’s of no actual concern and the tape helps maintain them clear and safe.  Once you might be executed with this wire splice, your work beneath the sprint is full ….YEAH!  (I want they made extra room beneath there!)

If you adopted the entire steps thus far, you need to have one LONG yellow wire that isn’t but hooked up to something and two white cables (each with three insulated wires inside). 

The white cables and the yellow wire are actually routed to the engine compartment since that is the place they should be related.  I choose to make use of the massive rubber plug that’s positioned on the fireplace wall, simply above the gasoline pedal.  I can account for a minimum of 9 wires or cables that penetrate this rubber plug on my TJ. 

The shorter of the 2 white cables can be related to the TJ’s velocity management servo.  The servo is positioned simply to the motive force’s facet of the grasp cylinder.  I made a decision to take away the manufacturing facility cable from the servo as it might be simpler to work on.  I eliminated the 2 bolts that maintain the servo to the its mounting bracket after which flipped the RED locking tab on the servo’s electrical connector (it pushes from left to proper within the above image).

With the locking tab unlocked, squeeze the plug and pull it from the servo’s connector.  This is a 4 wire plug and you’ll be connecting 3 of those wires to the brief white TWC cable.

Throttle Winch Control

Be cautious as you route these remaining wires via the engine compartment.  Keep them away from the world close to the exhaust manifold as this may simply soften the insulation and trigger issues.  Likewise, maintain your wiring away from shifting elements (belts, pulleys, throttle linkages, and fan blades).  Do not route your wires in such a way that causes tight bends on sharp surfaces (sheet metallic and such).  Using the after market wire protectors is a good suggestion and offers an additional measure of safety in your wiring. 

I slipped open the manufacturing facility cable protector to show three of the 4 wires that can be related to the pink, white, and black wires within the brief white TWC cable.  We used the provided splice connectors and hooked up the wires in line with the TWC set up instructions.  Nothing tough right here until you might be colour blind!

With the wires spliced collectively, electrical tape was utilized and every little thing was wrapped with a pair layers of tape.  The servo cable was then rerouted to its earlier place and the velocity management servo was hooked up to the bracket. 

The remaining white TWC cable can be related to the winch.  The set up instructions present a typical connection for a Warn winch.  I’d suggest that you simply confirm your winch connections match these within the instructions.  This can simply be executed with an ohm meter.   Connect one ohmmeter result in the Warn winch hand controller connector.  You can be utilizing the bottom, winch in, and winch out pins as proven within the instructions.  Connect the opposite ohmmeter result in the highest of the solenoids as proven within the instructions.  You ought to present 0 ohms between the suitable connector pin and its corresponding solenoid terminal.  My Warn 9000i  matched the diagram within the TWC set up instructions.  Make certain yours does too.

To take away the duvet on the Warn 9000i, take away each prime bolts (one on all sides) from the facet of the facet of the winch.  You could have to loosen the opposite two bolts (on only one facet) in order that the duvet might be eliminated.  If you don’t have a Warn winch with the built-in solenoids, you’ll have to decide how you can open the solenoid field and proceed with that Winch mannequin.  Again, I’ll point out that you’re simply connecting three winch management wires, floor, winch in, and winch out.  If you will have a wiring diagram in your winch, you need to be capable to extract the relevant info from it.

Here is a peak of what the 9000i seems to be like with its lid eliminated.  Be cautious if you find yourself completed and go to switch the duvet…..you don’t need to pinch any of the prevailing or new management wires beneath the lip of the duvet.

Since we had simply eliminated the duvet, Mike advised that now can be an excellent time to drill a gap within the cowl.  He talked about that I didn’t need to get the crimp on connectors on the tip of the cable and THEN notice that we hadn’t routed the cable via the duvet.  Good level!  We used a 1/4″ drill bit after which inserted the plastic grommet into the outlet.  The cable was then routed via the outlet and lower to an acceptable size.

NOTE:  I’ll confess right here that I didn’t catch the sentence within the TWC set up instructions that stated to drill the outlet within the facet of the winch’s solenoid compartment.  IMO, it makes no distinction as soon as you might be executed.

Throttle Winch Control

I couldn’t fairly get the nut driver into the right place so I loosened a few the heavy battery connections to make some room.  You can see the black (floor), white (winch out), and pink (winch in) wires related to the suitable solenoid terminals on my 9000i.

While I notice that the Warn winch cowl is just not water tight, we determined to place a pair dabs of silicone sealer on across the cable penetration.  We additionally put a cable tie on the within and out of doors in order that the cable couldn’t be pulled or pushed via the duvet.  The winch cowl was fastidiously put again into place (be sure to don’t pinch any wires) and the bolts changed.  Make certain to tighten any bolts that had been beforehand loosened.

You have one remaining wire, that lengthy yellow one,  from the TWC field that should be related to the camshaft place sensor.  I seen that there was no image for a 6 cylinder TJ with a distributor within the set up instructions.  No biggie…the one for 4 cylinder was shut sufficient for me.  (OK, I’ll confess once more and point out that I checked my ”98 FSM simply to verify I used to be splicing the proper wire.)  

The remaining splice connector is used to connect the yellow TWC wire to the tan/yellow wire popping out of the distributor housing.  Once once more, I used electrical tape to wrap every little thing up and supply some safety.  Be cautious as you route the yellow wire via the engine compartment.  The feedback I made earlier apply equally nicely to this wire too.

Mike needed to go away simply after we completed with the winch connections so he wasn’t there for the ultimate checkout.  I’m completely satisfied to report that every little thing labored identical to the operations part of the proprietor’s handbook acknowledged.  I began the automobile and first tried the throttle management.  It was too cool to see the engine RPMs ramp up and down as I performed with the correct hand group of cruise management buttons.  With that out of the best way, I had my spouse attempt the opposite group of switches.  Sure sufficient, the winch powered out and in, identical to it was suppose to. 

I put my instruments away and cleaned up the plethora of zip tie snipits and known as it full!  Just to verify all was nicely, I took it for a drive and made certain the manufacturing facility cruise management nonetheless functioned because it had.  No downside there….it labored simply high-quality.

Total set up time was about 7 hours.  We took our time taking photos and discussing wire routing paths.  When ever Mike and I get collectively, there’ll all the time be some off matter discussions which does nothing to additional the progress of our wrenching challenge…..which was demonstrated on a number of events throughout this set up.  But hey, I already stated I actually get pleasure from Saturdays and particularly these after I get an opportunity to spend it with Mike.  Before I neglect, thanks Mike for all the assistance.  I sit up for the following time.

In abstract, I’m very happy with the TWC from Kwan Motorsystems.  I had an opportunity, earlier than receiving the TWC, to change e-mail with them they usually had been most useful in answering my questions.  Although I’ve had no “issues” (and I don’t anticipate too), I’ll say that the client assist I’ve acquired so far (pre-sale) was second to none.  I sit up for making an attempt it out on the path.

Update October 07,2003

After posting this write-up on the JeepsUnlimited discussion board, one of many members inquired about the kind of interface it has with the Warn winch.  It appears that Warn has a problem with one of many aftermarket wi-fi winch controllers that’s made by one other firm.  I contacted Kwan Motorsystems they usually had been good sufficient to ship me the next info in regards to the TWC.

Most Warn winches (the older ones don’t) have a redundant swap association.  I don’t understand how the radio/wi-fi distant is designed, however the TWC has the identical redundant hook up just like the Warn distant, nevertheless it makes use of MOSFETs.

I’ve included an image of the similarities between the Warn distant and the TWC. The 5 management wires are labeled 1, 2, 3, 4, 6 (whole 5 wires) in reference to the pictured connector (winch connector face not the distant connector).